Composite upholstery fabric panels with enlarged graphite intumescent particles

ABSTRACT

Fabric layers and composite articles that incorporate graphite-containing coatings that do not stain are provided. A fabric layer for use as a flame and heat blocking component of an upholstered article includes intumescent graphite particles that are configured to swell and char in the presence of flame so as to form a barrier to flame, hot gases and heat for a predetermined period of time. The graphite particles have a size greater than about 150 microns which prevents the particles from being drawn to a surface of an upholstered article during sewing and quilting operations.

RELATED APPLICATION

This application is a divisional application of pending U.S. patentapplication Ser. No. 11/431,384 filed May 10, 2006, which isincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to textiles and, moreparticularly, to fire resistant textile products.

BACKGROUND OF THE INVENTION

Various textiles used in the clothing, furnishings and industrialfabrics industries are fire-unstable, i.e., they burn or melt orotherwise heat-degrade when in contact with flame or heat. For example,woven, knitted, and non-woven constructions of cotton, viscose, rayon,synthetics such as polyester, natural/synthetic blends and wool may burnor melt in the presence of flame or heat.

The application of flame retardant treatments to textiles, nonwovens,papers, and the like, is well known. Flame retardant fabrics may betreated in such a way that they do not ignite, or support combustion, orthey may be treated to provide “flame blocking” properties. Flameblocking materials not only do not support combustion, but also canfunction to protect objects that are flammable or that can be damaged byfire.

Flame blocking materials can have many forms. For example, flameblocking materials may be composed of non-combustible materials likeasbestos, glass, metal, or may be composed of organic materials likepara-aramid, melamine, polybenzimidazole, or other materials that haveresistance to flame and heat, or may be composed of combustiblematerials that are treated chemically to resist fire and heat. Anintumescent material will tend to char, swell, and form a barrier toflame, hot gases, and conductive heat transfer. Exemplary intumescentmaterials include, but are not limited to, melamine, pentaerythritol,fluorocarbon, graphite, bentonite, clay, phosphated or borated melamine,ammonium polyphosphate polyols and the like.

Intumescent coatings are described in Intumescent Coating Systems, TheirDevelopment and Chemistry by H. L. Vandersall, J. Fire & Flammability,Vol. 2 (April 1971), pp. 97-140, which is incorporated herein byreference in its entirety. The application of an intumescent material totextiles is usually carried out by conventional techniques, such asknife coating, roll coating, spray coating, calendering, transfercoating or screen printing.

U.S. Pat. No. 5,645,926 to Horrocks et al. describes a flexible fire andheat resistant material comprising an intimate mixture of organicintumescent filler and organic fibres adapted to char intensely withinthe temperature range of 200° C. to 500° C.

U.S. Pat. No. 4,923,729 to Porter et al. describes a method forincreasing heat dissipation from the smolder or open flame site of anupholstered article by interposing a fire barrier material between theouter upholstery fabric and the filler or padding materials. The firebarrier material is formed by coating a fibrous substance, such as glassfibers, carbon fibers, and the like with a latex containing a finelydivided heat conductive metal.

U.S. Pat. No. 5,830,319 to Landin describes a flexible fire barrier feltand a method of producing the fire barrier felt. The felt includes: atleast about 10 weight percent (wt-%) of an organic polymeric binder; atleast about 5 wt-% of organic fibers having pendant hydroxyl groups(preferably cellulosic fibers); and at least about 10 wt-% of a heatabsorbing compound; wherein the felt contains at least about 0.3 wt-% ofphosphorus, as provided by a phosphorus-containing compound.

U.S. Pat. No. 5,070,119 to Nugent, Jr et al. describes an intumescentcurable composition which contains as a resinous binder a flexiblepolyepoxide resin. The intumescent curable composition is usually in theform of a thick material such as a mastic and is spray applied to asubstrate.

U.S. Pat. No. 6,153,668 to Gestner et al. describes a method of making afire barrier material comprising the steps of (a) providing componentscomprising at least about 25 wt-% binder, at least about 10 wt-%intumescent compound, and at least about 5 wt-% organic fiberscomprising an organic material having pendant hydroxyl groups, based ona total dry weight of the fire barrier material; (b) combining thecomponents to form a mixture; (c) foaming the mixture; (d) placing thefoamed mixture onto a substrate; and (e) drying the foamed mixture for atime sufficient to form the fire barrier material, wherein the firebarrier material has a density ranging from greater than zero to about0.35 g/cm³. Once the mixture has been formed into a foam-like material,it is placed or applied onto a substrate, for example, by casting,pouring, or spreading. Placing or applying the mixture onto a substratecan be accomplished by casting the mixture onto a substrate and thenpressing it to a desired thickness by means of a platen press, or it canbe poured or cast into a mold lined with a release liner.

U.S. Pat. No. 6,265,082 to Dunham et al. describes a fire retardantcomposition consisting of a cured film, wherein the film is formed froma film-forming composition comprising a curable resin and at least onefire retardant, the fire retardant being included in an amount fromabout 5 to about 95 percent by weight based on the weight of the curedfilm, and wherein, when the film is adhered to a flexible substrate, thefilm substantially does not alter the hand of the flexible substrate.

U.S. Pat. No. 4,806,185 to Porter et al. describes a method forincreasing heat dissipation from the smolder or open flame site of anupholstered article. The upholstered article comprises an outer fabricthat houses and contains filler materials such as padding. The methodinvolves interposing a fire barrier material between the decorativeouter upholstery fabric and the filler materials. The barrier materialcompletely envelops the filler material and can be woven or nonwoven andis made of coated fibrous substances, such as glass fibers, carbonfibers, polyaramid, polybenzimidazole, polymeta-phenylene diamineisophthalate, and combinations thereof. The coating consists of a latexof enhanced thermal conductivity containing a finely divided heatconductive metal such as aluminum, copper, nickel, and mixtures thereof,with the proviso that the outer upholstered fabric has a porosity ratingof less than 10 cubic feet of air per minute per square foot, measuredat a pressure of one-half inch of water. The amount of heat conductivemetal can vary from about 4 to 20%, and preferably about 8 to 10% byweight of the coating composition. The fire barrier fabric can alsofunction as an effective fire barrier with for example, bedspreads,quilts or mattress ticking, and the like. The outer face fabric and thefire barrier fabric can be attached sequentially to a cushion orfurniture frame. Alternatively, a prelaminated fabric consisting of theface fabric can be adhesively laminated to the fire barrier fabric. Thefire barrier fabric can also be sewn to an outer face fabric.

U.S. Pat. No. 4,824,709 to Tschirch describes a textile product having atextile material and a backcoating comprised of a polymer matrix andinorganic smoke suppressant and/or flame retardant intumescentparticles. The backcoating may also contain an inorganic filler thatfurther enhances the flame retardancy and low smoke properties of thetextile product. The methods of forming the textile product includemixing the smoke suppressant and/or flame retardant intumescentparticles with the backcoating prior to its application to the textilematerial or the simultaneous spreading of the particles on the textilematerial with the polymer backcoating in order to form a layer of theparticles directly adjacent to the textile material.

U.S. Pat. No. 4,216,261 to Dias describes a process for imparting anintumescent, water repellent, fire retardant finish that is applied byconventional coating techniques to one side of a fabric. The treatedmaterial is then dried at temperatures in the range 222° F. to 260° F.

U.S. Pat. No. 3,889,022 to Whittaker et al. describes a flame-retardantcomposite article having a core of one or more combustible materials, atleast partly covered by a combination of one or more flexibleintumescent char-forming materials, and one or more textile fibrouslayers.

Expandable graphite is a particularly effective intumescent material.Graphite to be used as an intumescent material is conventionally treatedwith an acid (e.g., sulfuric, nitric, acetic acid, etc.) which permeatesthe layers of the graphite structure and causes the graphite to becomeexpandable and form a thick insulative layer of carbon char when exposedto flame. When a substrate, such as a nonwoven, knit, or woven fabric,is coated with a layer of material containing expandable graphite, thecoating will expand and form a thick char when exposed to fire, heat,hot gases, or molten materials, and effectively block the progress of aflame. Unfortunately, when fabrics having graphite-containing coatingsare processed into composite upholstery articles (e.g., panels for usein mattress construction) via sewing and/or quilting, the graphite tendsto stain the surfaces of the composite articles.

FIGS. 1A-1B illustrate a conventional composite upholstery panel 10having a ticking layer 12, a layer of resilient cushioning material 14,and a backing layer 16 with a coating 18 of material containingexpandable graphite. The ticking layer 12, cushioning material 14 andbacking layer 16 are quilted together in a pattern via thread 20,Graphite particles from the coating 18 work their way through thecushioning material 14 and the ticking layer 12 for example, via aquilting needle, and stain the ticking layer surface 12 a adjacent tothe quilting thread 20, as illustrated. The staining is indicatedgenerally as 22.

Graphite staining is particularly troublesome when upholstery panelshave white and other light-colored outer layers (e.g., ticking layers).Unfortunately, light-colored ticking layers and covers are preferred inmany upholstery industries including the bedding industry. As such,graphite is typically not used as an intumescent material in the beddingindustry.

However, because graphite is an effective intumescent material, it wouldbe desirable to be able to utilize graphite in the various upholsteryindustries where white and other light-colored fabrics are utilized.

SUMMARY OF THE INVENTION

In view of the above, fabric layers and composite articles thatincorporate graphite-containing coatings that do not stain are provided.According to an embodiment of the invention, a fabric layer for use as aflame and heat blocking component of an upholstered article includesintumescent graphite particles that are configured to swell and char inthe presence of flame so as to form a barrier to flame, hot gases andheat for a predetermined period of time. The graphite particles have asize greater than about 150 microns which prevents the particles frombeing drawn to a surface of an upholstered article during sewing andquilting operations.

According to embodiments of the present invention, a compositeupholstery panel includes a layer of ticking fabric, a layer ofresilient cushioning material, and a layer of backing fabric having acoating of intumescent material disposed on a surface thereof. Thecoating includes expandable graphite particles greater than 150 micronsin size and that resist adherence to needles and thread and passagethereof through the layer of cushioning material and ticking layer. Theticking layer, cushioning layer, and backing layer are quilted togetherwith thread that forms spaced-apart patterns of stitches extending alongthe composite upholstery panel. The graphite particles do not stain theticking layer and, when exposed to flame, char and swell to form abarrier to flame, hot gases, and heat for a predetermined period oftime.

Possible uses of composite panels and fabrics according to embodimentsof the present invention include, but are not limited to, fabrics,clothing, mattresses, upholstered or leather-covered furniture, andcommercial/transportation seating (e.g., airplane seating, trainseating, auditorium seating, etc.).

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which form a part of the specification,illustrate key embodiments of the present invention. The drawings anddescription together serve to fully explain the invention.

FIG. 1A is a plan view of a composite upholstery panel having a backinglayer, cushioning layer and ticking layer quilted together, and whereingraphite particles from a coating on the backing layer have stained thesurface of the ticking layer.

FIG. 1B is a cross-sectional view of the composite upholstery panel ofFIG. 1A taken along lines 1B-1B.

FIG. 2 is an enlarged cross sectional view of the composite upholsterypanel of FIG. 1A which illustrates graphite particles being drawn upthrough the cushioning layer by the needle and thread and beingdeposited on and adjacent to the surface of the ticking layer.

FIG. 3A is a plan view of a composite upholstery panel, according tosome embodiments of the present invention, having a backing layer,cushioning layer and ticking layer quilted together, and wherein acoating including large, expandable graphite particles is disposed onthe backing layer.

FIG. 3B is a cross-sectional view of the composite upholstery panel ofFIG. 3A taken along lines 3B-3B.

FIG. 4 is an enlarged cross sectional view of the composite upholsterypanel of FIG. 3A which illustrates no graphite particles being drawn upthrough the cushioning layer via the quilting needle and thread.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now is described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

Like numbers refer to like elements throughout. In the figures, thethickness of certain lines, layers, components, elements or features maybe exaggerated for clarity. Broken lines illustrate optional features oroperations unless specified otherwise. All publications, patentapplications, patents, and other references mentioned herein areincorporated herein by reference in their entireties.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. As used herein, the term “and/or”includes any and all combinations of one or more of the associatedlisted items. As used herein, phrases such as “between X and Y” and“between about X and Y” should be interpreted to include X and Y. Asused herein, phrases such as “between about X and Y” mean “between aboutX and about Y.” As used herein, phrases such as “from about X to Y” mean“from about X to about Y.”

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the specification andrelevant art and should not be interpreted in an idealized or overlyformal sense unless expressly so defined herein. Well-known functions orconstructions may not be described in detail for brevity and/or clarity.

It will be understood that when an element is referred to as being “on”,“attached” to, “connected” to, “coupled” with, “contacting”, etc.,another element, it can be directly on, attached to, connected to,coupled with or contacting the other element or intervening elements mayalso be present. In contrast, when an element is referred to as being,for example, “directly on”, “directly attached” to, “directly connected”to, “directly coupled” with or “directly contacting” another element,there are no intervening elements present. It will also be appreciatedby those of skill in the art that references to a structure or featurethat is disposed “adjacent” another feature may have portions thatoverlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is inverted, elements described as “under” or “beneath” otherelements or features would then be oriented “over” the other elements orfeatures. Thus, the exemplary term “under” can encompass both anorientation of “over” and “under”. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly. Similarly, the terms“upwardly”, “downwardly”, “vertical”, “horizontal” and the like are usedherein for the purpose of explanation only unless specifically indicatedotherwise.

It will be understood that, although the terms “first”, “second”, etc.may be used herein to describe various elements, components, regions,layers and/or sections, these elements, components, regions, layersand/or sections should not be limited by these terms. These terms areonly used to distinguish one element, component, region, layer orsection from another element, component, region, layer or section. Thus,a “first” element, component, region, layer or section discussed belowcould also be termed a “second” element, component, region, layer orsection without departing from the teachings of the present invention.The sequence of operations (or steps) is not limited to the orderpresented in the claims or figures unless specifically indicatedotherwise.

Applicant has unexpectedly discovered that staining can be dramaticallyreduced or eliminated in composite articles wherein expandable graphiteparticles are incorporated as an intumescent material if the graphiteparticles are increased in size from conventional sizes. Applicant hasdiscovered that staining does not occur if the particle size of thegraphite is maintained above about 150 microns. Although not fullyunderstood and not wishing to be bound by any particular theory.Applicant believes that graphite particles greater than about 150microns (50 mesh) in size are not capable of adhering to needles andthread used in sewing and quilting operations and/or are unable to passthrough fibrous layers of material. As such, graphite particles greaterthan about 150 microns are not transported to the surface of compositearticles.

FIG. 2 is an enlarged cross sectional view of the composite upholsterypanel 10 of FIGS. 1A-1B with a quilting needle 25 passing therethroughto quilt the layers of the panel 10 together via thread 20. The graphiteparticles 19 in the coating layer 18 have a size less than about 150microns which allows them to adhere to the needle 25 and thread 20 andto be drawn upwardly through the cushioning layer 14 and ticking layer12 and deposited on and adjacent to the surface 12 a of the tickinglayer 12.

Referring to FIGS. 3A-3B, a composite upholstery panel 110, according toembodiments of the present invention, is illustrated. The compositeupholstery panel 110 includes a layer of ticking fabric 112, a layer ofresilient cushioning material 114, and a layer of backing fabric 116having a coating 118 of intumescent material disposed on a surfacethereof. The coating 118 includes expandable graphite particles havingsizes that resist adherence to needles and thread and passage thereofthrough the layer of cushioning material 114 and ticking layer 112. Theticking layer 112, cushioning layer 114, and backing layer 116 arequilted together with thread that forms spaced-apart patterns ofstitches extending along the composite upholstery panel 110, asillustrated.

According to some embodiments of the present invention, the graphiteparticles in the coating 118 have sizes greater than or equal to 150microns. A preferable size range for the graphite particles is between150 microns and 1000 microns with an average particle size generallybetween about 250 microns and 350 microns. Preferably, no more thanabout one percent (1%) of the total graphite particles in the coating118 have a size less than 150 microns. When exposed to flame, thegraphite particles in the coating 118 are configured to expand at leastabout fifty times an original volume and form a barrier to flame, hotgases, and heat for a predetermined period of time.

Exemplary graphite particles that may be used in coatings in accordancewith some embodiments of the present invention include Nyacol Nyagraph251, from Nyacol Corp. Ashland Mass., Signature Graphite 7800B fromSuperior Graphite Co. of Chicago Ill., and Graphguard 220-50, fromGraphtech International, Lakewood Ohio. When preparing a coatingcontaining graphite particles, it is important not to create smallgraphite particles (i.e., graphite particles smaller than 150 microns)when mixing, foaming, stirring, or coating the graphite containingmixtures. Graphite content within the coating may range from about 5% toabout 50%, with 10% to 30% being a preferred range. At higher levels ofgraphite content, graphite particle size becomes even more importantwith regard to the potential for causing staining.

FIG. 4 is an enlarged cross sectional view of the composite upholsterypanel of FIGS. 3A-3B with a quilting needle 25 passing therethrough toquilt the layers of the panel 110 together via thread 20. Becauseaverage graphite particle size is greater than 150 microns, no graphiteparticles 19 are being pulled from the coating 118 via the quiltingneedle 25 and thread 20 and through the cushioning and ticking layers114, 116.

According to embodiments of the present invention, the backing fabric116 may be a fibrous layer of material, may be woven or nonwoven and maycontain one or more types of fibers. For example, the backing layer 116may be a nonwoven needlepunched fabric prepared from a blend ofnon-thermoplastic and thermoplastic fibers.

The coating 118 of intumescent material containing graphite particlesmay be applied to the backing layer 116 as a foam coating.Alternatively, the coating 118 may be applied as a paste coating. Anexemplary foam coating process includes aerating the coating materialusing mechanical stirring while injecting air. The use of air as adiluent creates a mixture that has a higher viscosity than the precursormaterial and helps the coating maintain a foam structure duringapplication to a substrate surface. The foam coating compound may thenbe applied using a knife or roller coater, reverse roll, slot coater,gravure coater, spraying, extrusion, dipping, or printing, each of whichis well understood by those skilled in the art.

The composition of coating 118 may be compounded with binders andthickeners and the like to aid in the specific application of thecoating. Additionally, flame retardant fillers such as aluminatrihydrate, silicates, kaolin, gypsum and hydrated clay may be added.

If a foam coating process is utilized, the foam coating process can bedesigned to retain the foam structure when dried, or to have the foamstructure rupture and disperse, leaving no foam structure in the driedcoating. However, a coating with a retained foam structure may bepreferred.

A technique for applying a foam coating containing expandable graphite,in accordance with embodiments of the present invention, is via aparabolic foam coating unit available from Gaston Systems, Inc.,Stanley, North Carolina, and which is described in U.S. Pat. Nos.6,395,088 and 6,508,882, both of which are incorporated herein byreference in their entireties.

The coating 118 may be dried using conventional means such as tentering,convection oven, infrared drying, flotation dryer or other common sheetor web drying equipment.

The layer of cushioning material 114 may be a foam material, a fibrousmaterial or a combination of foam material and fibrous material.

EXAMPLE 1

An exemplary formulation for a coating containing expandable graphite isas follows:

INGREDIENT % (ACTIVE) Water 39.8 Noveon MW 3141 (blend of 40.0 Acrylicbinder and clay) Titanium dioxide dispersion 3.0 Ammonium lauryl sulfate0.1 Nyacol Nyagraph 251 17.0 Acrysol TT-615 thickener 0.1This mixture is prepared at a viscosity of 3000-7000 cps, and thenfoamed to a blow ratio of about 2 parts air to 1 part mixture. Theresulting viscosity is 10,000-15,000 cps. This foam was coated on a 3.5ounce/sq. yd needlepunched nonwoven that was composed of 90% viscose,and 10% para-aramid fiber. The chemical add on is 6.64 ounces/sq yardwet, or 4.0 ounces/sq yard dry. This coated fabric is soft, hasexcellent flame blocking properties, and does not cause marking whenquilted or stitched.

EXAMPLE 2

If the same compound and coated fabric of Example 1 is prepared usingSuperior 7800 graphite, then the same soft, highly flame resistantcompound is produced but since this graphite has 3.15% small particlegraphite with sizes down to 45 microns or less, then the coated fabricwill stain the stitching thread, the needles, and small particles willbe extracted from the coating and deposited on the surface, which isunacceptable.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. The invention is defined by the following claims, withequivalents of the claims to be included therein.

1. A composite upholstery panel, comprising: a layer of ticking fabric;a layer of resilient cushioning material; and a layer of backing fabriccomprising a coating of flame blocking material disposed on a surfacethereof, wherein the coating comprises intumescent graphite particleshaving a size that prevents the graphite particles from being drawnthrough the cushioning material and ticking fabric and to a surface ofthe ticking fabric during sewing and quilting operations, wherein theintumescent graphite particles swell and char in the presence of a flameso as to form a barrier to flame, hot gases, and heat for apredetermined period of time; and wherein the ticking fabric, cushioningmaterial, flame blocking material, and backing fabric are quiltedtogether with thread that forms spaced-apart patterns of stitchesextending along the composite upholstery panel.
 2. The panel of claim 1,wherein the graphite particles have a size greater than or equal to 150microns.
 3. The panel of claim 1, wherein the graphite particles have anaverage size of from 250 to 350 microns, and wherein less than onepercent (1%) of the graphite particles have a size less than 150 microns4. The panel of claim 1, wherein the coating comprises a polymericbinder and acid-treated expandable graphite particles, and wherein thegraphite particles have sizes in the range from 150 microns to 1000microns.
 5. The panel of claim 1, wherein the graphite particles areacid-treated and are configured to expand at least about fifty times anoriginal volume when exposed to flame.
 6. The panel of claim 1, whereinthe cushioning material comprises foam.
 7. The panel of claim 1, whereinthe cushioning material comprises a fibrous layer of material.